1. Internship report
Company :
Almoiz sugar and power plant limited
Dera ismail khan
Submitted by :
Muhammad shahzad
Roll number :2012-ME-406
Submitted to :
Sir Imranniazi sb. (HOD mechanical )
2. Mechanical workshop :
Lath machine :
A lathe is a machine tool which rotates the workpiece on its axis to perform various
operations such as cutting, sanding, knurling,drilling, or deformation, facing, turning,
with tools that are applied to the workpiece to create an object which
has symmetry about an axis of rotation.
For tapering Ɵ= tan-1 D-d/L
There are 5 lath machines workshop.
Shaper machine :
A shaper is a type of machine tool that uses linear relative motion between
the workpiece and a single-point cutting tool to machine a linear toolpath.
3. Its cut is analogous to that of a lathe, except that it is (archetypally) linear
instead of helical.
It is used for making plumber blocks , key cavity,
Drilling machine :
(1)pedestald.m (2) radial drill machine
Radial drill machine
a machine in which the drilling head is mounted to slide along a radial arm which can b
e rotated, raised, orlowered on a vertical mast to adjust the position of the drill above th
e workpiece.
4. Pumps
1)centrifugal pump (2)rotatary pump (3)vacuumpump (4)reciprocating pump
Centrifugal pump:
Centrifugal pumps are used to transport fluids by the conversion of rotational kinetic
energy to the hydrodynamic energy of the fluid flow. The rotational energy typically
comes from an engine or electric motor. The fluid enters the pump impeller along or
near to the rotating axis and is accelerated by the impeller, flowing radially outward into
a diffuser or volute chamber (casing), from where it exits
Parts
5.
6. Rotary pump(MEGMA)
A rotary vane pump is a positive-displacement pump that consists of vanes mounted
to a rotor that rotates inside of a cavity.
It is used for sugar (leaker) displacement. Fluids
Grinder:
used in a machining operation to refine the surface of material
types:
Tool grinder, powerv grinder, pencil grinder, baby grinder,
7. Bearings:
A bearing is a machine element that constrains relative motion to only the desired motion, and
reduces friction between moving parts.
Types:
Bush bearing , ball bearing, roller bearing, thrust bearing, tapered roller bearing,spherical
bearings
8. Gears:
A gear or cogwheel is a rotating machine part having cut teeth, or cogs,
which mesh with another toothed part to transmit torque
types:
spur gear, helical gear, bevel gear , rack and pinion gear
Valves:
a mechanical device that controls the flow of liquid, gas, etc., by opening and closing
tupes:
1) gate valve 2) glove valve 3) butterfly valve 4)non return valve 5) duplex valve
9. 6) TC valve 7)safety valve 8)ball valve
Bolts
bolt is used to attach objects or structures to concrete
types
1)head bolts 2) LN key bolts 3)conster bolts 4)stud bolts , 5)raval bolts
11. Boiler section :
A boiler is a closed vessel in which water or other fluid is heated.
Types
1)water tube boiler 2)fire tube boiler
Water tube boiler
In this type, tubes filled with water are arranged inside a furnace in a number of
possible configurations, often the water tubes connect large drums, the lower
ones containing water and the upper ones, steam and water; in other cases,
such as a mono-tube boiler, water is circulated by a pump through a succession
of coils. This type generally gives high steam production rates, but less storage
capacity than the above. Water tube boilers can be designed to exploit any heat
source and are generally preferred in high-pressure applications since the high-
pressure water/steam is contained within small diameter
pipes which can withstand the pressure with a thinner wall.
Introduction
There are two high pressure and high temperature boilers operating in
Al-Moiz-1. These boilers were designed by ASME under SECTION-I
and manufactured under the standards of ASME SECTION-II. The type
of these boilers is “water tube boiler”. To further elaborate its working
and operation following explanation is made.
1. Boiler Parts and Specifications
Boiler is a heating device that uses heat energy to convert water into steam using multiple stage
process. It functionality and parts are discussed below.
1.1 Furnace
Furnace is the heart of the boiler it supply all the energy to the water tubes to convert the water
into the steam. It is like a big hall with headers surrounding it. These headers have tube in them
and these tubes contain water and steam in them. The heat from the furnace converts the water
into the steam. The headers that are located at the side the furnace contain water in them while
the headers at the top of the furnace contain the steam in them. Inside the furnace there is a
cyclone of hot air created by the inlet air coming from the secondary fan and hot air coming from
the air pre heater under the bagasse inlet chute.
12. The figure explains the working of furnace. At the top there is a Steam Drum that contains 50%
treated water and 50% steam. Water from the feeding pumps goes into the steam drum from here
water moves down into the headers (Total=27). When the water goes into the headers they come
into contact with the heat inside the furnace having a temperature of 800°C. The water in the
headers gets converted into the steam the steam moves up passing the water goes into the steam
drum. The steam goes into the steam drum. In steam drum steam has the temperature of 490°C
and pressure of 65bar. The set point for the safety valve to blow out the steam from the steam
drum is set at 67bar.
To understand the boiler following specifications of the boiler are given below.
Temperature
Steam temperature Feed water temperature Pressure Tanks Temp
490°C 125°C 5°C
Pressure
Design pressure Working pressure
75 bar 65 bar
Dimensions
Heating
surface-
Total
boiler
Capacitor
room
chamber
Evap-
orator
Super
heater
no. (01)
Super
heater
no. (02)
Air
heater
Econo-
mizer
Furnace
volume
Furnace
height
Furnace
width
1871𝑚3
578𝑚3 904
𝑚3
568𝑚3
284𝑚3 999
𝑚3
1453𝑚3
641𝑚3 125m 5m
Boiler Tubes
No. of Tubes Thickness mm Diameter mm
Front wall head tubes 113 tubes 4 63.5
Screen tubes 113 4 63.5
Rare back header tube 100 63.5
Side header tube 86+86=172 4 63.5
Evaporator Tube 101 3.6 42.4
Super Heater No. (01) 100 3.2 31.8
Super Heater no. (01)
Header external
diameter
21.44,
Length=11000mm
273.0
Header No. (02) Material=SA-335 15.09, Length External dia.=273.05
13. =11000mm
Front wall’s tube Material=SA-192 4 63.5
Rare wall’s tube Material=SA-192 4 63.5
Super Heater tubes Material=A213T11 3.2 31.8
Evaporator Tubes Material=SA-192 4 63.5
Screen tubes Material=SA-192 4 63.5
Economizer 3.2 31.8
Economizer No.(01) 29 Length=158800mm
Economizer no. (02) Length=106000mm
Furnace grate Total number of
shafts=90
Total stockers in each
shaft=39
Total stoker=3510
1.1.1 Stockers
There are total six compartments in the furnace of the boiler and each compartment contains
twelve stockers. So, total number of stockers in a furnace is seventy two (72). There are also
doors for each compartment having a thickness of 6 inches.
1.1.2 Pressure Actuator
There are two pressure actuators for each compartment. These actuator lifts up the stockers using
high pressure compressed air. Each compartment contains two actuators, one for six stockers.
1.2 Air Circulation
This boiler is designed to conserve maximum amount of energy. For that purpose air pre heater,
evaporator and two economizers are the part of it.
1.2.1 F.D/Primary Fan (Force Draft Fan)
The air from the atmosphere is taken in by the F.D fan. Air first passes through the air pre heater.
There are tubes of small diameter through which air passes while from the outside exhaust gases
pass. In this way exhaust gases further transfer its temperature to the incoming fresh air.
14. Motor=160KW and RPM=985/1000
Double Roller Bearing 22218EC3
Cylindrical Bor Plumber Block SKF.5NL-218
Capacity F.D=2300
𝑚3
𝑚𝑚2
1.2.2 Secondary Fan
Air after passing through the air pre heater gets distributed. Here there is a secondary fan that
takes the required air from the air pre heater. There is a “Damper” at the start of the duct of the
secondary fan. This damper have different opening that is used to increase and decrease the air
flow through the duct.
Double Roller Bearing EC322218
Cylindrical plumber block-SKF.5NL-218
Motor=90KW and RPM=1470
Capacity=1667𝑚3
Design pressure W.G=300kg/𝑚𝑚2
1.2.1 I.D Fan (Induced Draft Fan)
I.D fan help the exhaust gases to go out into the atmosphere passing through the economizers
and air pre heater. The motor that is driving the fan is VFD. I.D fan total Bladder=10+10=20
Double roller plumber block Cylinder boor plumber Coupling wing
22224EC3 block S.K.E-524-620 SNL 10×172×192mm
Motor capacity R.P.M Capacity
315KW (VFD) 990/1000 5400𝑚3
1.2.3 Under grate
The air that left after passing through the secondary fan goes into the under grate. This under
grate is a big duct of air from that air goes into the furnace passing through under the grate bars.
In this way a cyclone is generated inside the furnace. So, this will help the bagasse to come in
contact with the air more, resultantly into the good burning of the bagasse.
1.3 Bagasse Carriers
There are total four bagasse carriers
15. I. Main bagasse carrier number (02)-Bagasse coming from the bagasse elevator goes into
the main bagasse carrier number (02).
II. Main bagasse carrier number (01)-From main bagasse carrier number (02) bagasse
dropped into the main bagasse carrier number
(01). From here bagasse goes into the bagasse
inlet chutes.
III. Return bagasse carrier number (01)-Bagasse that
left behind after passing through the inlet chute
goes to the return bagasse carrier number (01)
IV. Return bagasse carrier number (02)-From return
bagasse carrier number (01) bagasse
1.4 Bagasse Inlet Chute
At the top of the furnace there are six inlet chutes of the solid fuel in each boiler. “Bagasse” is
used as a solid fuel in these boilers. Bagasse that comes from the bagasse carriers goes into these
bagasse chutes. At the end of these bagasse inlet chutes there are picker rollers that rotates
continuously so, the bagasse coming into the furnace comes in equal quantity. The arrangement
of the inlet chutes vary in the angles.
1.5 Economizer
Economizer is used to save the heat going out through the exhaust gases. It contains tubes
thathave water in it. Water from the steam drum goes into the tubes of the economizer. Exhaust
gases from the furnace go out passing through the economizer. These exhaust gases have a very
high temperature up to 480°C. When these gases pass through the economizer having water
tubes, they raise the temperature of the water inside the tubes of the economizer. This heat
transfer happens according to the principal of
convection.
2.0 Operation
The boiler works in a cycle. There are number of
steps to be followed as discussed below.
2.1 Lightning Up
First of all boiler furnace is lighten up with the
bundles of wood. These woods are lightened using
natural oil or the diesel. When the wooden pieces
catch up the fire Force Draft (FD) fan is started
slowly. This will help the smoke to go out through
the chimney. Also bagasse feeding through the
chute is started.
16. 2.2 Firing the boiler
When the bagasse from the chute starts coming into the boiler. It interacts with the fire already
created by the wood. This fire is further busted with the help of circulation of air in the form of
vortex generated by the I.D and Secondary fan.
2.3 Bagasse Chanel
Bagasse comes into the boiler with the help of bagasse carriers. There are total five bagasse
carriers to feed two boilers.
2.3.1 Main Bagasse Carrier No. (02)
Main bagasse carrier no. 02 starts right after the bagasse elevator. It has following specifications
Electrical specs
Motor Power Motor speed
160 KW 1470
2.3.2 Main Bagasse Carrier No. (01)
Main bagasse carrier No (01) is the main feeder of the both the boilers. As there are six chutes of
the boiler so, there are six inlet feeding paths all lie on the main bagasse carrier no. (01).
Motor Power Motor speed
110 KW 1470 RPM
It has same specifications and linear speed as carrier no. (02) Have. Its total length=95m and
linear velocity=88.57 ft/min.
2.3.3 Return Bagasse Carrier No. (01)
Return bagasse carrier carries the extra bagasse comes from main bagasse carrier no. (01).that It
has same specifications and linear speed as carrier no. (02) Have.
Motor Power Motor speed
75 KW 1470 RPM
It has same specifications and linear speed as carrier no. (02) Have. Its total length=95m and
linear velocity=88.57 ft/min.
2.3.4 Return Bagasse Carrier No. (02)
Return bagasse carrier No.(02) is used to bring the bagasse from the bagasse storage area. It is at
the very far end where feeding is carried out by the tractors.
Motor Power Motor speed
160 KW 1470 RPM
17. 2.3.5Down Bagasse Carrier
Down bagasse carrier is located after main bagasse carrier (01). This carrier carries the left over bagasse
from main carrier (01).
Water path:
Turbo pump(300) reverse osmosis plant(RO house ) pressure tank (900,
1.5 bar pressure )
Deratortank(feed water tank) 1250 , 2 bar pressure
feed water pumps(4 pumps multistage pressure 65 bar)
Economizer( 1500 , 65 bar pressur )
18. Steam drum(50% water and 50% steam )
Water header
Evaporator # 01,02
Steam drum super heater # 02,01(4900, 65 bar)
Steam drum (if tempreture is above 4900) (tcvalve )
19. Power house
Power house
Introduction
In Al-Moiz the power plant is having a capacity of 43MW. There are total three steam turbines
having following specifications
1. 16MW-Reaction Steam Turbine(back pressure )
2. 12MW-Reaction Steam Turbine(back pressure )
3. 15MW-Condensing Steam Turbine
Steam generation process is done at boilers where bagasse is used a fuel. Steam from boiler is
sent to the turbines at a pressure of 65bar and its capacity (80 ton/hr) vary as the load on the
generator of the turbine varies.
1) 12MW Reaction Steam Turbine
Operating Conditions
Driven equipment………………………………………………………………..Generator
Nominal Power………………………………………………………………….12000KW
Turbine Speed……………………………………………………………………1500rpm
Steam Condition
Inlet pressure……………………………………………………………………65bar(a) (Normal)
Inlet temperature………………………………………………………………..490°C
Exhaust pressure………………………………………………………………..3bar(a)
Industrial Steam Turbine Technical Features
Type……………………………………………………………………………..Back Pressure
Type of stages……………………………………………………………………Low Reaction
Normal Turbine Speed…………………………………………………………..9243rpm
20. Trip Speed………………………………………………………………………10167rpm
First critical speed……………………………………………………………….4200rpm
No. of emergency valves…………………………………………………………1
No. of control valves……………………………………………………………..4
Inlet connection………………………………………………………………….2×Ø150mm
Exhaust connection……………………………………………………………….Ø500mm
Normal control oil pressure………………………………………………………1.5
kg
𝑐𝑚2
Normal lubrication oil pressure…………………………………………………...30
kg
𝑐𝑚2
Gear Box Technical Features
Construction……………………………………………………Parallel/simple Reduction shafts
Input speed…………………………………………………………………………9243rpm
Output speed……………………………………………………………………….1500rpm
Reduction Ratio…………………………………………………………………….1:6.166
Service factor……………………………………………………………………….𝑓𝑠=1.10
Main Material-Turbine
Top high pressure turbine casing ………..……………………………………… GS-17(CrMov)
Bottom high pressure turbine casing…..…………………………………………GS-17(CrMov)
Integral rotor………………………………………… alloy steel 1% (CrMov)
Bearing linings………….……………………………………………………………..White metal
Gear Box
Top and bottom casings……………………………………………………………ASTM A4830C
Gears………………………………………………………………….……….....DIN 17CrNiMo6
Oil seals…….…………………………………………………………….………................Copper
Bearing linings…………...………………………………………………….………...Patent Metal
21. Turbine rotor sealing 12MW (liberenze)
First set 8 rings First ring big
Second set 12 rings First ring big
Third set 18 rings First ring big
Fourth set 24 rings First ring small
Ring Pressing
Both sides low pressure and high pressure side pressing rotor’s opposite direction.
Shaft size=220.11mm
Speed Control System
Digital Electronic Governor
Type………...………………………………………………….………..……Electrical/Hydraulic
Turbine protections :
Over speed Protection
(When load suddenly falls down then turbine speed become free and over speed occure.)
Vibration(indication sensor 0.7mm)
Lubrication oil( low pressure, high pressure ,flow,tempreture )
Axial displacement
2) 15MW Condensing Steam Turbine
15MW is also a combination of impulse and reaction turbine. It is made by China.
a) Control oil accumulator
Controls control oil inlet inside the accumulator. There is a bladder inside the
accumulator which contracts and expands as the pressure increases and decreases.
b) CPC
CPC is a black round box that controls turbine inlet steam.
c) Oil-Control Oil Filter
P=25MPa, Q=40L/min, Clearance=10µm
d) Vacuum Releasing Pipe
22. e) This releasing pipe releases the vacuum from inside the pipe. The water injected from the
top and this water creates the resistance in the vacuum and breaks the vacuum. But
usually it is not in working condition its valve is closed.
f) Steam inlet pipe from boiler
Steam is injected into the turbine to warm up the turbine at P=30-40
kg
𝑐𝑚2
and temperature
up to 350-400°C.
Load on the generator of the turbine varies from 2MW to 8MW similarly the condensate level
varies from 250mm to 350mm according to the flow of inlet steam.
EFFICIENCY OF STEAM TURBINE
To calculate the efficiency of the turbine, Enthalpy must be know at the inlet and at the outlet of
the turbine.
Enthalpy=The sum of the internal energy of the system plus the product of the pressure of the
gas in the system and its volume.
H= U + PV
H=Enthalpy (KJ)
U=Internal Energy (KJ)
P=Pressure (N/𝑚2
)
V=Volume of gas (𝑚3
)
To find the efficiency following relation is used,
23. η 𝑡=
ℎ1−ℎ2
ℎ1−ℎ2𝑠
……..(A)
η 𝑡= Turbine efficiency
ℎ1=Inlet enthalpyℎ2=Outlet enthalpy
ℎ2𝑠 =Specific enthalpy
So, efficiency of the 12MW turbine at the maximum working parameters
Inlet Temperature=490°C
Inlet Pressure=65bar
Outlet Temperature=180°C
Outlet Pressure=3bar (maximum) is
𝛈 𝒕=75.4%
24. Boiling house
Juice cycle
Mill house
Juice
Primary heater(1)(600
-750
)
Defication Tank(680
-700
)
CaO lime mixing and milk of bomi (60
-80
)
Secondary Juice heater(1030
-1050
)
Slush Tank
Clearifier(polyelectric light chemicalmixing)
1) Clear Juice 2) mud
Clear juice
25. Clear juice tank(13-14 bricks)
Prejuiceheater(1100
-1150
)
Body no 1(falling film evaporator)
(22-25 bricks )
In tubes juice passes but besides tubes
steam passes and and converted into
hot water and sent to sagar tank.
Body no . 2 (30-35 bricks )
Body no .3 (40-45 bricks)
Body no.4 (50-55 bricks )
Body no. 5 (60-65 bricks)
Body no . 6
26. Syrup tank
A massicuite (A grain+syrup mixing and development ,
steam passed) PAN(7,8,9)
crystallizer pump pugmill continuous
centrifugal machine
1) A.Sugar 2) molasisA.heavy
A.Sugarremelt(raw leaker)
TeloclearifierPressure filter concentrators (mini
evaporaors for leaker to make more thick) refine pan
Refine crystallizer Refine massecuite
c.f pump refine pugmill batch type c.f
machine
run off molassis
wet sugar hopper dryer elevatot
bagging sugar grader
refine pan mingler fine sugar seed
27. MILL HOUSE
Feeding tables
Carrier number (chain moves by sprocket by motor
on which cane carries)
Shalader
Diffuser
Mill machine
1) Juice 2) baggass
28.
29. M.T workshop
Engine power distribution system ,air conditioning system. Break system,water
circulation system, radiator, lub oil system,self,generator, cluch system, gear
system,
